Careless assembly, dangerous as well.
We purchased a factory new trailer. We found these factory defects:
Dangerous defects: (1) 3 way refrig was NOT installed according to manufacture's direction. The unit was NOT sealed to prevent carbon monoxide and other combustion gas byproducts from entering the trailer when refrig was operating on propane. Gaps at top and bottom were so wide my hand easily slid between Forrest River cabinet & refrig. There was NO exhaust gas deflector to direct gases out through the exterior vent panel. The floor of the microwave oven was NOT sealed to prevent exhaust gases from entering the cabin. (2) Tires are improper load range: 1700 pounds at 50 psi. Dry weight of the trailer is 3375 pounds. Maximum load exceeds the combined carrying capacity of the 2 tires even after deducting tongue weight. Tire disintegrated on a recent trip. (3) Propane heater was installed improperly. Instead of constructing a solid bed upon which the unit rest, the unit was installed with a narrow wooden board at the front (interior) end and the remaining weight was entirely supported by the inlet and exhaust pipes at the rear of the heater. These pipes are welded onto the heater. The exhaust pipe becomes very hot during use and the weld will eventually fail allowing carbon monoxide to enter the trailer.
Other non-lethal issues:
1. Upon collecting the trailer we found ALL faucets leaking and the drain in the bathroom sink disconnected because pipe to the holding tank was cut too short.
2. The breather pipe to the bathroom shower &sink holding tank leaked (we filled the clean tanks to determine leakage and this tank spilt water into the trailer).
3. The toilet was secured to the floor by 1 of 2 screws allowing it to rock side-to-side.
4. The medicine cabinet in the bathroom dropped off the wall after a trip. It was secured into 1/8 inch plywood with wood screws pointing upwards, instead of downwards. . .still 1/8th inch plywood is entirely inadequate for the load.
5. All paneling is secured only by staples, and many panels worked lose with normal use.
6. Wooden stick framing was installed inside the trailer, workers did NOT clean out the saw dust which continued to leak into the cabin during road trips.
7. Failure to seal necks of both toilet and shower holding tanks where the necks enter the trailer allowed road wind to enter the cabin and blow the saw dust about.
8. The toilet holding tank had 2 sets of holes drilled into the floor; the first set was placed in the wrong spot, and NOT covered; thereby allowing wind to enter and potentially rodent and reptiles.
9. None of the electrical wire was as the wiring plan indicated.
10. There was no 40A fuse in the converter to allow the convert to charge the battery.
11. The black thin metal fascia around the bottom of the trailer (exterior) was NOT supported by struts. One side blew off during a drive in a strong wind.
12. ALL shelving is 1/8th inch plywood, and ALL shelves collapsed with very light and normal load.
13. The common electrical grounds from the battery to the trailer frame are fewer than 5 inches from the tires. When the tire exploded, a piece of tire severed one ground; thus disabling the slide-out.
14. Neither of the two metal tire wheels (these isolate the tires from the trailer's insides) were installed properly. BOTH had gaps of 1/2 - 3/4 inch, allowing wind and rain to enter the trailer.
Several repairs I had performed under warranty. These were quickly approved and cost Forrest River approximately $4, 000 total. Those repairs that involved the dangerous and potentially lethal issue, because of my engineer's training, I performed.
In short, Forrest River produced a product that out their factory door was unsafe and unfit for use. There appears to be no quality control and the workers appear to be thoroughly disinterested in quality. The accounts appear to manage the company and will take all opportunities to increase initial profits while disregarding the back-end cost of warranty service.
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